Abstract:

This invention relates generally to a composite fabric and a method and
apparatus for manufacturing a composite fabric, especially suitable for
apparel application, upholstery, bed and bath applications. In an
embodiment, a composite fabric comprises a base fabric made by weaving or
knitting. A plurality of gaps is disposed in-between the fibers of the
yarns of the base fabric. A plurality of functional fibers is entangled
in the gaps followed by swelling of the fibers, with predetermined
retention to the yarns of the base fabric.

Claims:

1. A composite fabric, comprising:(i) a base fabric made by weaving or
knitting;(ii) a plurality of gaps disposed in-between the fibers of the
yarns of the base fabric wherein a plurality of functional fibers are
entangled in the gap with predetermined retention to the yarns of the
base fabric.

2. A composite fabric according to claim 1 further comprising a plurality
of functional fibers locked in-between the yarns of the base fabric.

3. A composite fabric according to claim 2 further comprising a plurality
of functional fibers in mutually entangled configuration.

4. A composite fabric according to claim 1 wherein the entangled
functional fibers and the fibers of the yarns of the base fabric are
permanently swollen.

5. A composite fabric according to claim 1 wherein the base fabric
comprises at least one of a natural or a synthetic fiber.

6. A composite fabric according to claim 1 wherein the functional fiber is
selected based on required properties and application of the composite
fabric product.

7. A composite fabric according to claim 6 wherein the functional fiber
includes at least one among the group consisting of phase change fiber,
anti-microbial fiber, eco-friendly fiber, regenerated fiber, cotton,
bamboo, nylon, silk, polyester and wool.

8. A composite fabric according to claim 6 wherein the fabric product is
at least one among an apparel, upholstery, bed and bath fabric product.

9. A composite fabric manufacturing apparatus, comprising:(i) at least one
first entanglement unit for stabilizing a base fabric;(ii) at least one
second entanglement unit for entangling a plurality of functional fibers
into the yarns of the base fabric, wherein the entanglement units are
configured having a plurality of injectors and perforated drums operating
at predetermined operating parameters so as to lock the functional fibers
into the yarns of the base fabric.

10. An apparatus according to claim 9 wherein the drums are covered with
sleeves having openness in the range of about 20% to 80%.

11. An apparatus according to claim 9 further comprises a means for
maintaining the dimensional stability of the stabilized base fabric.

12. An apparatus according to claim 9 further comprises a means for
squeezing the composite fabric.

13. An apparatus according to claim 9 further comprises a unwinding unit
configured having a means for continuous monitoring and control of the
original dimensions of the base fabric.

14. A composite fabric manufacturing method, comprising:(i) stabilizing
and forming gaps in-between fibers in the yarns of a base fabric, using a
fluid jet of predetermined first pressure;(ii) entangling a plurality of
functional fibers in the gaps using fluid jet of predetermined second
pressure wherein the functional fibers are coupled to the yarns of the
base fabric with predetermined retention.

15. A method according to claim 14 wherein the fluid jet comprises water.

16. A method according to claim 14 wherein the first pressure is in the
range of about 20 bar to 250 bar.

17. A method according to claim 14 wherein the second pressure is in the
range of about 60 bar to 400 bar.

18. A method according to claim 14 wherein the length of the fluid jet is
in the range of about 6 mm to 12 mm.

19. A method according to claim 14 wherein the jet size is in the range of
about 0.07 mm to 0.3 mm.

20. A method according to claim 14 wherein the yarns are spun with
substantially low twist levels and/or with substantially shorter and
coarser fibers.

Description:

FIELD OF THE INVENTION

[0001]This invention relates generally to a composite fabric and a method
and apparatus for manufacturing a composite fabric, especially suitable
for apparel application, upholstery, bed and bath applications.

PRIOR ART

[0002]Conventional textile fabrics are produced mainly through weaving and
knitting technology. This value chain starts from fiber selection and
development/modification so as to bring them to a spinnable form. This is
followed by spinning of the yarns. Many spinning technologies are known
in the art. However, ring spinning is the most versatile and dominant
one. Compact spinning is the latest advancement in this ring spinning
technology. Spinning is followed by weaving or knitting process wherein
yarns are interlaced or intermeshed together to form a fabric.

[0003]Woven fabrics are interlaced structures involving two series of
threads i.e. warp and weft at right angles to each other. The fabric
properties are governed by its constructional parameters like yarn count,
thread density, yarn crimp, weave and area density which is a function of
all other parameters. Fabrics are woven with variety of structures like
plain, twills, ribs and combinations thereof. Woven fabrics find a wide
range of applications as apparels like denims, bottom weights, shirting,
ladies dress material etc. Compared to knitted fabrics, woven fabrics are
well known for their graceful appearance, crease recovery and drape. But
the properties like thermal insulation, water vapor permeability & air
permeability are poor in these constructions because of compact
structures resulting from the pressure of interlacing at the cross over
points. In order to make these fabrics more functional with respect to
insulation properties and water vapor transmission, wrinkle free, etc
structural modifications need be done in combination with suitable
additional materials/chemicals.

[0004]On the contrary, knitted fabrics are intermeshed structures, which
are developed from a single source of yarn. They can be weft knitted or
warp knitted. Since there is no axial alignment of threads in knitted
fabrics they lack the gracefulness as in case of woven fabrics. Thus, the
drape is poor and these fabrics are soft to handle. Most of these fabrics
in use are weft knitted and preferred for next-to-skin inner garments or
as casual wear. The crease recovery of these fabrics is also poor.

[0005]Thus, in order to improve aesthetics of these constructions without
affecting their basic functionality, reinforcement may be provided which
is loose in construction and has open fiber configuration. Knitted
fabrics can find wide spread applicability with all desirable functional
properties and dimensional stability as a formal wear.

[0006]Additional function can be introduced in a basic fabric through the
structural modifications or through chemical finishes. While modifying
the parent woven and knitted fabric structures, it should always be borne
in mind that the basic properties should not be affected. The
structure-property inter-relationships are so intense in textile
materials, that one property cannot be altered in isolation from all
other properties. Further, route of chemical finishes has a limitation of
life of finish and also the fabric doesn't remain eco-friendly

[0007]Thus, the most appropriate approach is to achieve optimization with
respect to all functional properties at the same time taking into
consideration the economic aspects of production. A composite textile
fabric is the best solution. While the composite structure results in
better functionality, composite structures can be made out of combination
of woven and/or knitted and for nonwoven fabrics or layers.

[0008]Nonwoven is a latest technology of forming fabric directly from
fibers and/or filaments. It involves first step of preparation of web of
fibers and/or filaments followed by the bonding of the fibers so as to
form a fabric. Chemical bonding and thermal bonding are the known
methods. Fabrics made through these processes are very stiff and lag in
handle and feel and not suitable for any application next to human skin.

[0009]Known composite fabrics include at least one layer of a non-woven
fabric added on as a fused or interlined layer on a base fabric made of a
woven or knitted material. Some composite fabrics include a sandwiched
non-woven layer in-between two woven, knitted or any other synthetic
layers. However, both need to be produced separately in the beginning and
then should be bonded together in a separate process either by using
chemicals or by means of heat or by stitching. Also these layers always
tend to behave as separate entities and the characteristics of the two
layers may not be complementing each other. Additionally it is a long and
expensive process to produce a composite fabric.

[0010]Thus, there exists a need for a composite fabric wherein (i) the
fabric is soft and lofty and suitable apparel textile (ii) air
permeability is excellent and controllable (iii) the fabric could be made
using fibers which otherwise could not be made through conventional
textile processes (iv) the fabric has improved tensile strength and
bursting strength (v) throughput of the textile machine is improved (vi)
obtains reduced value chain.

[0011]Further, conventional composite fabrics, methods and systems for
manufacture of the same do not provide a fabric (i) wherein induced
stresses in the fabric are substantially minimized without repositioning
of the yarns and/or reduction in dimensions of the finished fabric (ii)
hygienic and eco-friendly method of manufacturing a composite fabric
(iii) a composite fabric whose strength and properties can be adjusted
during manufacture so as to suit desired application (iv) a significantly
wider range of application as against traditional textiles.

SUMMARY

[0012]In an embodiment, a composite fabric comprises a base fabric made by
weaving or knitting. A plurality of gaps is disposed in-between the
fibers of the yarns of the base fabric. A plurality of functional fibers
is entangled in the gap, with predetermined retention to the yarns of the
base fabric.

[0013]In an embodiment, a composite fabric manufacturing apparatus
comprises at least one first entanglement unit for stabilizing a base
fabric. At least one second entanglement unit is provided for entangling
a plurality of functional fibers into the yarns of the base fabric. The
entanglement units are configured having a plurality of injectors and
perforated drums operating at predetermined operating parameters so as to
lock the functional fibers into the yarns of the base fabric.

[0014]In an embodiment, a composite fabric manufacturing method comprises
stabilizing and forming gaps in-between fibers in the yarns of a base
fabric using a fluid jet of predetermined first pressure. A plurality of
functional fibers is entangled in the gaps using fluid jet of
predetermined second pressure wherein the functional fibers are coupled
to the yarns of the base fabric with predetermined retention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015]FIG. 1 shows a cross-section of a composite fabric according to an
embodiment of this invention.

[0016]FIG. 2 shows an embodiment of an apparatus for manufacturing a
composite fabric according to this invention.

[0017]FIG. 3 shows a flowchart of a method for manufacturing a composite
fabric according to an embodiment of this invention.

DETAILED DESCRIPTION OF THE INVENTION

[0018]Various embodiments of this invention provide a composite fabric.
Further embodiments of this invention provide a method and apparatus for
manufacturing a composite fabric. However, the embodiments are not
limited and may be used in connection with various applications that will
be described in later part of this specification.

[0019]FIG. 1 shows a cross-section of an embodiment of a composite fabric
according to this invention, wherein the composite fabric (5) comprises a
base fabric (1) made by weaving or knitting. A plurality of functional
fibers (7) is coupled with predetermined retention to the base fabric
(1). A plurality of gaps are disposed in-between the fibers of the yarns
(3) of the base fabric (1). A plurality of functional fibers (7) is
locked (entangled) into the gaps in-between the fibers of the yarns (3).
A plurality of the functional fibers (7) is locked in-between the yarns
(3) and the functional fibers (7) are also mutually entangled.

[0021]FIG. 2 shows an embodiment of an apparatus for manufacturing a
composite fabric according to this invention, wherein the apparatus
comprises a preparatory unit (80) for opening a bale of functional fibers
(7) (not shown in FIG. 2) and feeding it on to a carding unit (90). The
carding unit (90) converts the functional fibers (7) into the form of a
web (110) and feeds on to a belt (120) that transports the web (110) to
an entanglement unit (140). The web (110) obtained has predetermined
properties such as, uniformity, linear density for example, in the range
of 8 gm/m2 to 130 gm/m2, fiber orientation for example,
completely random orientation up to 5:1 direction. It should be noted
that the properties of the web (110) are controlled so as to obtain
composite fabric properties like tensile strength, stiffness, recovery
from the wrinkles, etc. The base fabric (1) is unwound by a fabric
un-winder (10). The fabric unwinder (10) delivers the base fabric (1)
under predetermined tension to an entanglement unit (130) maintaining the
base fabric width. The tension in the base fabric (1) may be set in the
range of 0 to 250 gms.

[0022]In an embodiment, an entanglement unit (130) comprises at least one
perforated drum (D1) with or without sleeve and at least a pair of
injectors (132). This entanglement unit (130) stabilizes the base fabric
(1) and delivers the base fabric (1) to the next entanglement unit (140).
A compaction belt (150) is provided to combine and compact the stabilized
base fabric (1) and the web (110) from the carding unit (90). This is
followed by entanglement of the functional fibers from the web (110) into
the base fabric (1) thus forming a composite fabric (5). This
entanglement is done using a plurality of drums (D2-D4) and injectors
(142, 152, 162) at predetermined operating parameters. This is followed
by a squeezing unit (160) that squeezes and removes excess water from the
composite fabric (5) thus formed and delivers the composite fabric to a
drying unit (170). The drying unit (170) comprises a plurality of steam
heated drying cans and/or air-heated drums. Thus dried composite fabric
(5) is wound on to a composite fabric winder (190).

[0023]FIG. 3 shows an embodiment wherein a composite fabric manufacturing
method comprises preparing a web (110) of functional fibers using the
preparatory unit (80) and the carding unit (90). The base fabric (1)
selected is in unfinished grey or semi-finished or finished form. A fluid
jet for example, water jet at predetermined pressure (example 20 bar up
to 250 bar) is used for pre-wetting and entanglement of yarns in the base
fabric (1) preferably at the cross over (intermeshing/interlacement)
points and also reorganize the fibers in the yarns of the base fabric (1)
to relax the prevailing stresses in the base fabric (1) thereby making
the base fabric (1) stable.

[0024]Furthermore, in an embodiment of the method of manufacturing a
composite fabric, the repositioning/reorganizing of the fibers
simultaneously opens out the yarn structure in the base fabric (1). The
opening out of the yarn structure in the base fabric (1) increases the
surface area to generate additional space among the fibers to accommodate
functional fibers (7) for entanglement.

[0025]In some embodiments, the fibers in the yarns of base fabric (1) may
be treated with chemicals such as, caustic soda, ammonia, etc so as to
facilitate availability of extra space for the functional fibers (7) to
reside into. The base fabric (1) with yarns made out of partly or fully
with the synthetic fibers may be heat set to stabilize and some times
initiate the preliminary yarn-to-yarn and fiber-to-fiber bonding.

[0026]In some embodiments, fibers, yarns and/or the base fabric (1) itself
may be treated with chemical adhesives, binders, etc so as to activate
the surfaces thereby facilitating improved entanglement strength.

[0027]In some embodiment, fibers, yarns and base fabric (1) may be treated
with plasma so as to activate the surfaces thereby facilitating improved
entanglement strength.

[0029]In an embodiment, the yarns (3) of the base fabric (1) are spun with
low twist levels (3% to 6%) and/or with much shorter and coarser fibers.
This enables more yarn diameter and more free space among the fibers of
the yarns (3). This also helps in fiber movement and creation of
additional space during entanglement and stabilization of the base fabric
(1). This helps in entangling more proportion of functional fibers (7)
into the gaps among the fibers in the yarns of the base fabric (1).

[0030]Thus stabilized base fabric (1) is laid with functional fibers (7)
from the web (110) followed by compacting.

[0031]A series of fluid jets at predetermined pressure (example 60 bar up
to 400 bar) is used for entanglement of functional fibers (7) from the
web (110) with the base fabric (1). In the process, functional fibers (7)
are systematically separated out from the web followed by pushing them
preferably in a single fiber form into the gaps created among the fibers
in the yarn. For those functional fibers (7), which do not get this
opportunity, are assembled in a proper format followed by their
entanglement with the already entangled functional fibers (7) and at the
end amongst themselves. For example, the number of fluid jets is at least
two. This step is followed to lock the functional fibers 7 into the gaps
in-between the fibers of the yarns (3). A plurality of the functional
fibers 7 is locked in-between the yarns and the functional fibers 7 are
also mutually entangled.

[0032]The high-pressure fluid jet is impacted on the base fabric (1) such
that the fluid jet penetrates into the fibers of the yarn (3). The
penetrated fluid jet further gets reflected at substantially in all
directions from the surface of the sleeve or the surface of the
perforated drum (D1) through the fibers in the yarn (3). The fibers in
the yarn (3) get reoriented/reorganized wherein during such
repositioning/reorganization of the fibers, the fibers absorb the energy
from the fluid jet and thereby get relieved of their stresses and also
reach to the minimum energy position.

[0033]The wet base fabric (1) delivered by the entanglement unit (140) is
uniformly squeezed so as to remove excess water and at the same time
facilitate further pushing of partially pushed-in functional fibers (7)
into the spaces still available in the yarns and in the base fabric (1).
In case of surface activated base fabric (1), the squeezing helps in
creating uniform bonding thereby improving entanglement strength. The
squeezing helps in reducing the overall weight of the composite fabric
being offered for the drying under a predetermined tension. This weight
reduction and reduction of mobilizing agent like water enables the
reduction of the possibilities of weakening of entanglement points before
they are frozen during drying.

[0034]A plurality of functional fibers is entangled to the base fabric (1)
from at least one side of the base fabric (1).

[0035]In an embodiment, the perforated drums (D1-D4) are covered with
sleeves with predetermined openness (example 20% up to 80%). This is one
of the factors to control the entanglement strength.

[0036]The length of the fluid jet (example 6 mm up to 12 mm) decides the
entanglement strength. For example, lower the length of the fluid jet,
the entanglement strength initially increases followed by more scattering
of the functional fibers (7) due to severe reflection from the surface of
the drum and the sleeve, with further reduction thereby resulting into
reduction of the entanglement strength.

[0037]A vacuum slot (6 mm up to 14 mm) in the perforated drum (D1) decides
the amount of reflection of the fluid jet from the surface of the sleeve
or the perforated drum (D1) and thereby the entanglement strength.

[0038]In an embodiment, the number of jets per inch is in the range of 10
up to 120. The jet size is in the range of 0.07 mm up to 0.3 mm. The
number of rows of jets is in the range from 1 up to 3. These parameters
decide the way of entanglement and the entanglement strength.

[0039]In an embodiment, the through-put rate of 10 m/min up to 100 m/min
decides the residence time of entanglement zone on the composite fabric
(5) and thereby the entanglement strength.

[0040]In an embodiment, the number of passes through the entanglement unit
(140) also decides the entanglement strength. For example, increased
number of passes will result in improved entanglement strength to an
optimum. Further additional passes start deteriorating the entanglement
strength and also composite fabric (5) becomes more stiff comparable to
paper material.

[0041]In an embodiment, in the entanglement unit (140), on drum (D4)
another side of the composite fabric (5) is treated by at least a pair of
high-pressure fluid jets (example 20 bar to 120 bar) and preset
parameters (0.07 mm to 0.12 mm jet size, 40 to 80 holes/inch, etc) to a
necessary level thereby achieving the necessary surface effects require
for apparel, upholstery, bed and bath applications.

[0042]In an embodiment, on the drum (D4), by selecting suitable sleeve and
fluid jets, various surface effects such as striking off of loose hairs,
loose color, embossing, aperturing effects may be created on the
composite fabric suitable for apparel, upholstery, bed and bath
applications.

[0043]In an embodiment, on drum (D4), by adjusting one of the fluid jets,
at an angle (example 20 deg to 35 deg) to the drum and fabric surface
thereby combing the yarn surfaces very effectively. This arrangement may
be used for creating the effects equivalent to pitching or emery finishes
on the composite fabric (5) surface suitable for apparel application.

[0044]The composite fabric (5) made according to this invention may be
further processed using chemicals or heat so as to lock and freeze the
entanglement points to a necessary level thereby achieving a balance
between elastic and plastic movement.

[0045]Thus, according to the principles of this invention, the composite
fabric can be made at an affordable cost in the following way.

[0046]Tear and Tensile strength of the base fabric (1) can be improved
substantially by virtue of realizing the strength of fibers directly from
the non-woven web combined with the base fabric (1). The composite fabric
(5) can be made isotropic or anisotropic by controlling non-woven web
geometry. Therefore, there is no need to use expensive fibers.

[0047]Fabric body can be improved, for example, a 11-ounce fabric can be
made to feel like 14-ounce fabric. This can be achieved through web
geometry and level of entanglement with base fabric (1).

[0048]Complete dimensions of the fabric can be retained to as close as
possible to the loom/manufacturing stage dimensions with the achievement
of best dimensional stability. Functional fibers from the web (110) which
are locked into the yarn structures of the base fabric (1) will freeze
the yarn positions as they are, resulting into minimal shrinkage
potential and best dimensional stability.

[0049]Keeping the OE based fabrics, flatness and washdowns of ring yarns
based fabrics may be obtained. Also, economical stretches can be
developed through this route and flat washdowns can be achieved.

[0051]Also, there will be a great opportunity for bringing down the raw
material cost. The usage of expensive fibers can be curtailed in the
conventional fabric process and can be supplemented by proper selection
of fibers, web geometry, hydro-entanglement energy and number of passes
through the hydro-entanglement process. This is a most economical way.

[0052]Conventionally, functions are introduced in the fabric by way of
chemical finishes that do not stay long. Expensive functional fibers are
blended with regular fibers. And one doesn't have a direct control on
fiber position in yarn structure. Accordingly, there will not be a
complete realization of benefits of these functional fibers. Also, if the
fibers are of different origin, will call for dyeing of both which would
be an expensive proposal.

[0053]In an embodiment, according to this invention, in a composite
fabric, we can place only required quantity of fibers at the right place
and realize the complete benefits. Also, in case of backside functional
layer, the fibers selected need not be dyed or else one can use predyed
fibers and initiate the action. Since these fibers are of only adequate
quantity and are properly entrapped into yarn structures, the fibers will
stay long enough and offer functions for a substantial long time.
[0054]Functions that can be inculcated are as follows: [0055]High
absorbency for comfort [0056]High wicking, transportation and release for
high comfort [0057]High wicking, transportation and slow release for
temperature regulation [0058]Entrap heat for warmth [0059]Wrinkle free
[0060]Wrinkle resistant [0061]Stretches [0062]Vegetable fiber based
functional fabrics [0063]Fluorescent/Reflective exteriors [0064]Metal
fiber based antibacterial, antimicrobial, antifungal
[0065]Protective/Filtration [0066]Stain, water, oil Repellent/Resistant

[0067]According to the principles of this invention, the applications of
the composite fabric may include:

[0097][0098]1. DP 4 [0099]2. PCM shirts [0100]3. Durable
functionalities through functional fibers and Expresso® technology.
[0101]4. OE to Ring shirts [0102]5. Plasma activated yarn dyed shirts.
Plasma activation will help high exhaustion rates and thereby reduction
in dyes and chemical consumption. This will reduce the loss of yarn
strength. Overall this will result into deeper and darker shades at lower
cost. Possibly, one can also save on fiber cost. [0103]6. Long life
chemical finishes using Plasma activated shirting fabrics [0104]7.
Electronics integrated shirts [0105]8. Semi durable and durable shirts
using staple fiber web and Expresso technology with or without support of
chemicals. [0106]Furthermore, according to the principles of this
invention, the upholstery applications include: [0107]1. Lightweight and
fine yarn based jacquard structured fabric stabilized with or without web
--Expresso®. These fabrics in original form are highly unstable and
very delicate. These can be stabilized, strengthened using Expresso®.
[0108]2. Machine washable microweight upholstery fabrics--using
Expresso® alone this can be achieved. [0109]3. Pre-washed and
stabilized Indigo micoweight upholstery--can be achieved by selecting
proper combination of jet strips, pressures. Effect is generated on
fabric face side and while going through this process whole fabric will
get dimensionally stable. [0110]4. Stiffness without coating and chemical
finishes can be inculcated in the fabrics by using 10 GSM webs with MD:
CD of 10:1 and heavily entangling the two together. This will add up the
necessary stiffness and unidirectional drape. [0111]5. High durability
and anti pilling--By simple Expresso® and with proper selection of
entanglement parameters, the surfaces of the fabric can be made very
tough. [0112]6. Fire resistant and Fire proof upholstery--By selecting
Aramid fies like NOMEX or Asbestos based fibers and entangling the
required web gsm on face side of the fabric these properties can be
achieved. Further, by using embossing and aperturing technologies of
Expresso®, surface looks can be engineered. [0113]7. Water and stain
repellent--This can be achieved by entangling required gsm of web of low
melting temperature fibers like PP on back side in such a way that
intentionally few % of fibers are allowed to project thru the fabric onto
face side. Using these fibers the whole structure can be thermally bonded
with water repellent films like PE, POLYESTER, NYLON etc to make the
surface water and stain repellent. [0114]8. UV repellent Upholstery--By
using UV repellent treated polyester fibers on the face side, this fabric
function can be achieved. GSM of the web will be optimized between look
and function level. [0115]9. Absorb light and convert it into heat
upholstery--This can be achieved through optically sensitive fibers
available in Japan. The web can be on face or back side of the fabric.
[0116]10. Fragrance release upholstery--This can be achieved thru
temperature sensitive fragrance release chemicals doped during extrusion
of fibers. Using web of these fibers, this function can be achieved.
Further, it can be made sensitive to temperature that is interactive.
[0117]11. Antistatic Upholstery--By using a thin web of antistatic fibers
on both face and backside of the fabric, this effect can be achieved.
[0118]12. Durable non woven upholstery--Embossed & or/apertured
cotton/blended nonwoven fabric by at least 15% followed by resin spot
bonding will meet this requirement. By using long staple synthetic
polyester/Nylon fibers and higher level of entanglement, one can also
generate durable non-woven upholstery. Also by hydroentanglement of light
bonded spunbond nonwoven fabric, one can produce durable upholstery.
[0119]13. E-Upholstery--by embedding various e-components while doing
Espresso, one can generate a range of smart upholstery. [0120]14.
Heat-proof table tops and upholstery--this can be achieved by bonding
asbestos/carbon/aramid fibers on the top surface and soft bulky 100%
cotton/blend layer at bottom. [0121]15. Wind proof curtains--this can be
achieved by controlling the porosity in the web through right selection
of fiber properties, web geometry and entanglement/aperturing parameters
of Espresso. It can be 100% non-woven or composite also. [0122]16. Highly
Breathable upholstery--This can pass on the heat and air very fast. This
can be achieved by controlling the parameters as described in point 15.
[0123]17. Mosquito repellent upholstery--this can be achieved thru
polyester/viscose fibers with mosquito repellent finish. [0124]18.
Hygienic upholstery--this can be achieved through Expresso® process
and also by using antibacterial antimicrobial and antifungal finished
fibers in the web and the web can be bonded on the required side of
composite upholstery fabric. [0125]19. Disposable table tops, sofa covers
and window laminates--these are functional one time usage non-wovens.
[0126]20. Highly absorbent table-tops--these can be produced using 3
layered composite durable/semi durable non-wovens and woven/knitted and
non-woven composites. [0127]21. Anti-termite dosing upholstery--this can
be done using polyester/nylon fibers with suitable finishes and may be
activated thru e-controls or temperature based or light based release
mechanisms. [0128]22. Anti-mite upholstery--this can be done using split
fibers and multilayer non-wovens. [0129]23. Anti-cockroach
upholstery--this can be achieved thru polyester/nylon fibers doped with
suitable finishes and the fibers can be on the operating surface of the
product. [0130]24. Anti-spider upholstery--this can be achieved thru
polyester/nylon fibers with suitable finishes and fiber can be on the
operating side of the product. [0131]25. Structured upholstery--this can
be through two routes, [0132]A. Non-woven on the top and woven on bottom
side--limit of imagination=limit of options. Different
embossing/aperturing tools can be used to generate the effects. Further
options can be thru differential bonding levels at different locations
resulting into "n" number of effects. [0133]B. Woven fabric on top and
non-woven on bottom--using jacquard one can generate required designs.
The design and fabric structure will be consolidated by Espresso. Fibers
can be functional or aesthetic support through different web geometries
[0134]Different colored fibers [0135]Different shrinkage behavior fibers
[0136]Fibers piercing thru the fabric onto face side [0137]Different
levels of bondings=different effects. [0138]C. This can be a woven
fabric alone--use all Espresso variables like [0139]Jet strips
[0140]Pressures [0141]Oscillating jets [0142]Block the jets at preferred
locations [0143]Different embossing sleeves.

[0144]Fibers and additives undoable through conventional processes can be
done using the principles of this invention and be made as the integral
part of the base fabric (1).

[0145]Further, aperturing, embossing tools of this non-woven fabric can be
used for enhancing further the base fabric using the principles of this
invention. For example, (i) wash and remove Indigo/Sulphur from the
selected areas on the fabric and generate various patterns, logos, etc on
face side of fabric (ii) Emboss the patterns and generate different look,
touch and feel of the fabric (iii) offer pre-washed fabric wherein one
can vary the level of wash, uniformity of wash and also generate virtual
optics during wash. This can be achieved through proper selection of jet
pressures, throughput rates, and different embossing sleeves. If the need
be, fabric can be apertured in different patterns using different
aperturing sleeves.

[0146]However, one can take any fabric, define a function, get right fiber
and/or additives hydro-entangle the composites together using right
combination of parameters. In the apparel textiles, upholstery, towels
and wipes, conventional textile process doesn't need much changes
implying easy to get through. We can use all types of staple fibers
manmade, natural, etc. Also, one can use powders/very small fibers like
wood pulp, paper pulp, etc and find out new applications. This is a 100%
hygienic process since it uses water in the form of high pressure jets to
bond the composites. Accordingly, products are hygienic.

[0147]The fear of pilling or poor abrasion resistance or peeling off of
layers does not exist, as there is no 100% non-woven fabric. Fibers from
the web (110) are pushed through and are entrapped into yarn structure of
the base fabric (1). Also, the right combination of web GSM, Fiber type,
web geometry, hydro-entanglement energy levels, entanglement time and
number of passes will result into trouble free composite fabric (5).

[0148]Various applications of the composite fabric includes durable stain
and water repellent fabric using film/membrane and staple fibers, work
wear and protective wears, long life chemical finishes using plasma
activation technology, semi durable and durable goods.

[0149]Thus, various specific embodiments of this invention provide a
method and a system for treating a fabric. Further embodiments of this
invention provide a method for manufacturing a composite fabric and a
composite fabric thereof.

[0150]Various modifications of this invention are possible. However, it
will be recognized by those skilled in the art that all such
modifications have been deemed to be covered by this invention and are
within the spirit and scope of the claims appended hereto.

Patent applications in class Including strand which is stated to have specific attributes (e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous composition, water solubility, heat shrinkability, etc.)

Patent applications in all subclasses Including strand which is stated to have specific attributes (e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous composition, water solubility, heat shrinkability, etc.)